American Water Works Association

ANSI/AWWA C509-94
(Revision of ANSI/AWWA C509-87)

AWWA STANDARD
FOR
RESILIENT-SEATED GATE VALVES
FOR WATER SUPPLY SERVICE

All changes specified in addendum AWWA C509a-95 are incorporated into this standard.

Effective date: Nov. 1, 1994.

First edition approved by AWWA Board of Directors Jan. 28, 1980.
This edition approved Jan. 30, 1994.
Approved by American National Standards Institute Aug. 18, 1994.

AMERICAN WATER WORKS ASSOCIATION

6666 West Quincy Avenue, Denver, Colorado 80235

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 AWWA Standard
This document is an American Water Works Association (AWWA) standard. It is not a specification.
AWWA standards describe minimum requirements and do not contain all of the engineering and
administrative information normally contained in specifications. The AWWA standards usually con-
tain options that must be evaluated by the user of the standard. Until each optional feature is
specified by the user, the product or service is not fully defined. AWWA publication of a standard
does not constitute endorsement of any product or product type, nor does AWWA test, certify, or
approve any product. The use of AWWA standards is entirely voluntary. AWWA standards are
intended to represent a consensus of the water supply industry that the product described will
provide satisfactory service. When AWWA revises or withdraws this standard, an official notice of
action will be placed on the first page of the classified advertising section of Journal AWWA. The
action becomes effective on the first day of the month following the month of Journal AWWA publi-
cation of the official notice.

American National Standard

An American National Standard implies a consensus of those substantially concerned with its scope
and provisions. An American National Standard is intended as a guide to aid the manufacturer, the
consumer, and the general public. The existence of an American National Standard does not in any
respect preclude anyone, whether that person has approved the standard or not, from manufactur-
ing, marketing, purchasing, or using products, processes, or procedures not conforming to the stan-
dard. American National Standards are subject to periodic review, and users are cautioned to
obtain the latest editions. Producers of goods made in conformity with an American National Stan-
dard are encouraged to state on their own responsibility in advertising and promotional materials
or on tags or labels that the goods are produced in conformity with particular American National
Standards.

CAUTION NOTICE: The American National Standards Institute (ANSI) approval date on the front
cover of this standard indicates completion of the ANSI approval process. This American National
Standard may be revised or withdrawn at any time. ANSI procedures require that action be taken
to reaffirm, revise, or withdraw this standard no later than five years from the date of publication.
Purchasers of American National Standards may receive current information on all standards by
calling or writing the American National Standards Institute, 11 W. 42nd St., New York, NY
10036; (212) 642-4900.

Copyright © 1994 by American Water Works Association

Printed in USA

ii
Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 Committee Personnel
The AWWA Standards Committee on Gate Valves and Swing Check Valves,
which reviewed and approved this standard, had the following personnel at the time
of approval:
Joseph J. Gemin, Chair
Thomas M. Bowen, Vice-Chair
Roland L. Larkin, Secretary

Consumer Members

R.E. Behnke, St. Louis County Water Company, St. Louis, Mo. (AWWA)
T.M. Bowen, Manchester Water Works, Manchester, N.H. (AWWA)
M.H. Burns, Denver Water, Denver, Colo. (AWWA)
S.F. Gorden, Portland Water District, Portland, Maine (NEWWA)
Cassandra Hamvas, Los Angeles Department of Water & Power,
Los Angeles, Calif. (AWWA)
C.H. Kersey, Detroit Water & Sewer Department, Detroit, Mich. (AWWA)
T.W. Knowlton,* Salem–Beverly Water Supply Board, Beverly, Mass. (NEWWA)

General Interest Members

E.E. Baruth,† Standards Engineer Liaison, AWWA, Denver, Colo. (AWWA)

K.M. Bell, Underwriters Laboratories Inc., Northbrook, Ill. (UL)
T.J. Brown Jr., Factory Mutual Research Corporation, Norwood, Mass. (FMRC)
K.J. Carl, Baldwin, N.Y. (AWWA)
R.L. Claudy Jr., Orlando, Fla. (AWWA)
J.B. Donohoe, Birmingham, Ala. (AWWA)
C.R. Dugan,† Council Liaison, Board of Water & Light, Lansing, Mich. (AWWA)
J.V. Fonley, Orange, Calif. (AWWA)
J.J. Gemin, Proctor & Redfern Ltd., Kitchener, Ont. (AWWA)
T.C. Jester, Consultant, Birmingham, Ala. (AWWA)
S.J. Medlar, Camp, Dresser & McKee Inc., Edison, N.J. (NEWWA)
E.F. Straw, ISO Commercial Risk Services Inc., Duluth, Ga. (ISO)

Producer Members

Jerry Bottenfield, Clow Valve Company, Oskaloosa, Iowa (MSS)

G.L. Bouc, Mueller Company, Decatur, Ill. (AWWA)
L.R. Dunn, U.S. Pipe & Foundry Company, Birmingham, Ala. (AWWA)
Les Engelmann, Ames Company Inc., Woodland, Calif. (AWWA)
R.L. Larkin, American Flow Control, Birmingham, Ala. (AWWA)
P.I. McGrath Jr.,* U.S. Pipe & Foundry Company, Birmingham, Ala. (AWWA)
M.P. Yoke, M&H Valve Company, Anniston, Ala. (AWWA)

*Alternate
†Liaison, nonvoting

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Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 Contents

SEC. PAGE SEC. PAGE

Foreword 4.11 Wrench Nuts and Handwheels....... 10

I History of Standard.......................... vi 4.12 Gearing............................................. 11
II Information Regarding Use 4.13 Gear Cases ....................................... 11
of This Standard ............................ vi 4.14 Indicators ......................................... 11
III Acceptance....................................... vii 4.15 Gaskets............................................. 11
IV Modification to Standard .............. viii 4.16 Valve Seats ...................................... 12
V Major Revisions ............................. viii
5 Fabrication
Standard 5.1 Workmanship................................... 12
5.2 Coating ............................................. 12
1 General
1.1 Scope................................................... 1 6 Testing, Inspection, and
1.2 Definitions .......................................... 1 Rejection
1.3 References .......................................... 2 6.1 Proof of Design Testing................... 12
1.4 Data to Be Supplied by 6.2 Production Testing .......................... 13
Manufacturer................................... 3 6.3 Plant Inspection and Rejection ...... 13
1.5 Affidavit of Compliance..................... 4
7 Marking and Shipping
2 Materials 7.1 Marking............................................ 14
2.1 General ............................................... 4 7.2 Preparation for Shipment ............... 14
2.2 Physical and Chemical
Properties ........................................ 4 Appendix

3 General Design A Installation, Operation, and

Maintenance of Resilient-
3.1 Structural Design .............................. 6 Seated Gate Valves
3.2 Size of Waterway ............................... 6
A.1 General ........................................... 15
4 Detailed Design
4.1 Parts to Be Made of Gray A.2 Unloading....................................... 15
or Ductile Iron................................. 6
4.2 Parts to Be Made of Brass A.3 Inspection Prior to
or Bronze ......................................... 6 Installation.................................. 15
4.3 Body and Bonnet ............................... 6
A.4 Storage............................................ 16
4.4 Bolting ................................................ 7
4.5 Valve Ends ......................................... 7 A.5 Installation
4.6 Guides................................................. 8
A.5.1 Bolts.................................................. 16
4.7 Stem and Stem Nut........................... 8
A.5.2 Underground Installation ............... 16
4.8 Stem Sealing ...................................... 8
A.5.3 Aboveground Installation................ 17
4.9 Packing ............................................... 9
A.5.4 Inspection ......................................... 17
4.10 Packing Glands, Gland Flanges,
A.5.5 Testing.............................................. 17
Gland Bolts, and Gland-Bolt
A.5.6 Records ............................................. 17
Nuts ............................................... 10

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Copyright (C) 1998 American Water Works Association, All Rights Reserved.
SEC. PAGE SEC. PAGE

A.5.7 Application Hazards ........................ 17 2 Minimum Thickness of Body

and Bonnet ...................................... 7
A.6 Inspection and Maintenance 3 Excess Flange Thickness .................. 8
A.6.1 Inspection ......................................... 18 4 Minimum Diameter of Stem and
A.6.2 Record Keeping ................................ 19 Minimum Number of Turns
to Open ............................................ 9
A.7 Repairs............................................ 19 5 Outside Diameter of
Handwheels................................... 10
Tables 6 Gear Ratios ...................................... 11

1 Chemical and Physical

Requirements for Bronze Used
in Resilient-Seated Gate Valves .... 5

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Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 Foreword
This foreword is for information only and is not a part of AWWA C509.

I. History of Standard. The resilient-seated gate valve has been commonly

used in several European countries for many years. This type of valve has proven to
be satisfactory in water utility applications. A resilient-seated gate valve similar to
the European model was introduced into the US market and has been in service in
various water utility applications since 1975.
The American Water Works Association (AWWA) requested the assistance of
the Manufacturers Standardization Society of the Valve and Fittings Industry
(MSS) in providing a standard for resilient-seated gate valves at the 1976 AWWA
annual conference.
MSS played an important role in the development of this standard. The organi-
zation was created in 1924, and in 1930 it organized the MSS Water Works Com-
mittee and designated representatives for appointment to AWWA standards
committees. Since that time, MSS has been particularly active and effective in
developing new standards for the water utility industry and in making periodic revi-
sions to existing standards.
II. Information Regarding Use of This Standard. It is the responsibility
of the user of an AWWA standard to determine that the products described in that
standard are suitable for use in the particular application being considered.
This standard includes certain options that, if desired, must be specified by the
purchaser. Also, several items must be specified to describe completely the gate
valve required.
The following summarizes the items the purchaser should cover in the pur-
chaser’s specifications and lists the sections in the standard where the items are
discussed.
1. Standard used — that is, AWWA C509-94, Standard for Resilient-Seated
Gate Valves for Water Supply Service.
2. Size and type of valve (Sec. 1.1).
3. Direction in which handwheel or wrench nut shall turn to open (Sec. 4.11.2).
4. Catalog data, net weight, and assembly drawings to be furnished by the
manufacturer (Sec. 1.4) if required.
5. Affidavit of compliance (Sec. 1.5) if required.
6. Quantity required.
7. If records of tests specified in Sec. 6 are to be furnished.
8. If the valve will be subjected to water that promotes galvanic corrosion and
requires the use of alternative materials as described in Sec. 2.2.4.4.
9. What alternative, if any, is desired in the type of rustproofing for bolts and
nuts (Sec. 4.4).
10. Type of valve ends — flanged (Sec. 4.5.1), tapping valve flange (Sec. 4.5.4),
mechanical joint (Sec. 4.5.2), or push-on joint (Sec. 4.5.3).
11. Type of stem seal — stuffing box or O-ring (Sec. 4.8).
12. Detailed description of wrench nut if not in accordance with Sec. 4.11.
13. Special cast markings (Sec. 7.1) if required.

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Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 14. If bolting material with physical and chemical properties other than
ASTM* A307 is required (Sec. 4.4). It is recommended that the purchaser verify
with the supplier the appropriateness of any alternative bolting materials required.
15. Cutter diameter must be specified for tapping valves (Sec. 3.2).
At the time this edition of AWWA C509 was approved, the US Environmental
Protection Agency (USEPA) had enacted regulations to reduce quantities of asbestos
fiber in the workplace and in the ambient air, thus lowering the exposure of the
general public to the health risks associated with asbestos inhalation. Language in
this standard no longer references the use of asbestos packing and gasket materials.
Users of AWWA C509-94 should comply with USEPA, state, provincial, and local
regulations regarding asbestos and consider the implications of using various alter-
native gasket and packing materials as listed in this standard.
III. Acceptance. In May 1985, USEPA entered into a cooperative agreement
with a consortium led by NSF International (NSF) to develop voluntary third-party
consensus standards and a certification program for all direct and indirect drinking
water additives. Other members of the consortium included the American Water
Works Association Research Foundation (AWWARF), the Conference of State Health
and Environmental Managers (COSHEM), the American Water Works Association
(AWWA), and the Association of State Drinking Water Administrators (ASDWA).
The consortium is responsible for the cooperative effort of manufacturers, regulators,
product users, and other interested parties that develop and maintain the NSF
standards.
In the United States, authority to regulate products for use in, or in contact
with, drinking water rests with individual states.† Local agencies may choose to
impose requirements more stringent than those required by the state. To evaluate
the health effects of products and drinking water additives from such products, state
and local agencies may use various references, including
1. An advisory program formerly administered by USEPA, Office of Drinking
Water, discontinued on Apr. 7, 1990.
2. Specific policies of the state or local agency.
3. Two standards developed under the direction of NSF, ANSI‡/NSF§ 60,
Drinking Water Treatment Chemicals — Health Effects, and ANSI/NSF 61, Drink-
ing Water System Components — Health Effects.
4. Other references, including AWWA standards, Food Chemicals Codex,
Water Chemicals Codex,** and other standards considered appropriate by the state
or local agency.
Various certification organizations may be involved in certifying products in
accordance with ANSI/NSF 61. Individual states or local agencies have authority to
accept or accredit certification organizations within their jurisdiction. Accreditation
of certification organizations may vary from jurisdiction to jurisdiction.

*American Society for Testing and Materials, 1916 Race St., Philadelphia, PA 19103.
†Persons in Canada, Mexico, and non-North American countries should contact the
appropriate authority having jurisdiction.
‡American National Standards Institute, 11 W. 42nd St., New York, NY 10036.
§NSF International, 3475 Plymouth Rd., Ann Arbor, MI 48106.
**Both publications available from National Academy of Sciences, 2102 Constitution Ave.,
N.W., Washington, DC 20418.

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Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 Appendix A, “Toxicology Review and Evaluation Procedures,” to ANSI/NSF 61
does not stipulate a maximum allowable level (MAL) of a contaminant for sub-
stances not regulated by a USEPA final maximum contaminant level (MCL). The
MALs of an unspecified list of “unregulated contaminants” are based on toxicity
testing guidelines (noncarcinogens) and risk characterization methodology (carcino-
gens). Use of Appendix A procedures may not always be identical, depending on the
certifier.
AWWA C509-94 does not address additives requirements. Thus, users of this
standard should consult the appropriate state or local agency having jurisdiction in
order to
1. Determine additives requirements, including applicable standards.
2. Determine the status of certifications by all parties offering to certify prod-
ucts for contact with, or treatment of, drinking water.
3. Determine current information on product certification.
IV. Modification to Standard. Any modification of the provisions, definitions,
or terminology in the standard must be provided in the purchaser’s specifications.
V. Major Revisions. The major revisions in this edition of AWWA C509
include the following:
1. Numerous modifications to conform to current AWWA form and content
have been added.
2. The “Modification to Standard” and “Acceptance” sections have been added
to the foreword.
3. Asbestos packing and gasket materials are no longer referenced in the
standard.
4. Information on tapping valves has been added.
5. Soft metric equivalents have been added.
6. Definitions have been modified.
7. The Safe Drinking Water Act 1986 Amendments reference to maximum
lead content in bronze has been added.
8. Repairs to castings of valve components have been clarified (Sec. 5.1.2.).
9. Discussion of 16-in. (400-mm) and 20-in. (500-mm) valves has been added
to the scope of this standard (Sec. 1.1.1).

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Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 American Water Works Association

ANSI/AWWA C509-94
(Revision of ANSI/AWWA C509-87)

AWWA STANDARD FOR

RESILIENT-SEATED GATE VALVES

FOR WATER SUPPLY SERVICE

SECTION 1: GENERAL
Sec. 1.1 Scope
This standard covers iron-body, resilient-seated gate valves, including tapping
gate valves, with nonrising stems (NRS) and outside-screw-and-yoke (OS&Y) rising
stems for water supply service.
1.1.1 Sizes. Gate valves covered by this standard are 3 in. (75 mm), 4 in.
(100 mm), 6 in. (150 mm), 8 in. (200 mm), 10 in. (250 mm), 12 in. (300 mm), 16 in.
(400 mm), and 20 in. (500 mm) nominal pipe size (NPS). Sizes refer to the nominal
diameter, in inches (or millimetres), of the waterway through the inlet and outlet
connections and the closure area.
1.1.2 Valve pressure rating. The minimum design working water pressure
shall be 200 psig (1,380 kPa [gauge]) for 3- through 12-in. (75- through 300-mm) size
and 150 psig (1,034 kPa [gauge]) for 16- and 20-in. (400- and 500-mm) sizes.
1.1.3 Conditions and materials not covered. This standard is not intended to
cover special conditions of installation or operation, such as built-in power drive,
installation in vertical or steeply inclined lines, conveyance of unusually corrosive
water, or excessive water hammer. Such conditions are beyond the intended scope of
this standard and require special consideration in design and construction. Joint
accessories for end connections, such as bolts, gaskets, glands, follower rings, and so
forth, are not covered in this standard.
Sec. 1.2 Definitions
In this standard, the following definitions shall apply:
1.2.1 Cosmetic defect: A blemish which has no effect on the ability of the com-
ponent to meet the structural design and production test requirements of this
standard. Should the blemish or the activity of plugging, welding, grinding, or

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
2 AWWA C509-94

repairing of such blemish cause the component to fail these requirements, then the
blemish shall be considered a structural defect.
1.2.2 Flanged joint. The flanged and bolted joint as described in
AWWA/ANSI* C110/A21.10 or ANSI B16.1, class 125.
1.2.3 Manufacturer: The party that manufactures, fabricates, or produces
materials or products.
1.2.4 Mechanical joint: The gasketed and bolted joint as described in
ANSI/AWWA C111/A21.11.
1.2.5 NPS: Nominal pipe size.
1.2.6 Purchaser: The person, company, or organization that purchases any
materials or work to be performed.
1.2.7 Push-on joint: The single rubber gasket joint as described in
ANSI/AWWA C111/A21.11.
1.2.8 Structural defect: A flaw that causes the component to fail the structural
design or test requirements of this standard. This includes, but is not limited to,
imperfections that result in leakage through the walls of a casting, failure to meet
the minimum wall-thickness requirement, or failure to meet production tests.
1.2.9 Tapping valve: A special gate valve designed with end connections and
an unobstructed waterway to provide proper alignment and positioning of a tapping
sleeve, valve, and machine for tapping pipe dry or under pressure.
Sec. 1.3 References
This standard references the following documents. In their latest editions, they
form a part of this standard to the extent specified herein. In any case of conflict,
the requirements of this standard shall prevail.
ANSI/Aerospace Standard† AS-568A — Aerospace Size Standard for O-rings.
ANSI/ASME‡ B16.1 — Cast Iron Pipe Flanges and Flanged Fittings, Class 25,
125, 250 and 800.
ANSI/ASME B16.10 — Face-To-Face and End-To-End Dimensions of Valves.
ANSI/ASME B18.2.1 — Square and Hex Bolts and Screws Inch Series Includ-
ing Hex Cap Screws and Lag Screws.
ASTM§ A27 — Standard Specification for Steel Castings, Carbon, for General
Application.
ASTM A126 — Standard Specification for Gray Iron Castings for Valves,
Flanges, and Pipe Fittings.
ASTM A153 — Standard Specification for Zinc Coating (Hot-Dip) on Iron and
Steel Hardware.
ASTM A307 — Standard Specification for Carbon Steel Bolts and Studs,
60,000 PSI Tensile Strength.
ASTM A395 — Standard Specification for Ferritic Ductile Iron Pressure-
Retaining Castings for Use at Elevated Temperatures.
ASTM A536 — Standard Specification for Ductile Iron Castings.

*American National Standards Institute, 11 W. 42nd St., New York, NY 10036.

†Society of Automotive Engineers, 400 Commonwealth Drive, Warrendale, PA 15096.
‡American Society of Mechanical Engineers, 345 E. 47th St., New York, NY 10017.
§American Society for Testing and Materials, 1916 Race St., Philadelphia, PA 19103.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 3

ASTM B154 — Standard Test Method for Mercurous Nitrate Test for Copper
and Copper Alloys.
ASTM B633 — Standard Specification for Electrodeposited Coatings of Zinc on
Iron and Steel.
ASTM B766 — Standard Specification for Electrodeposited Coatings of Cadmium.
ASTM D395 — Standard Test Methods for Rubber Property — Compression Set.
ASTM D429 — Standard Test Methods for Rubber Property — Adhesion to
Rigid Substrates.
ASTM D471 — Standard Test Method for Rubber Property — Effect of Liquids.
ASTM D1149 — Standard Test Method for Rubber Deterioration — Surface
Ozone Cracking in a Chamber.
ASTM D2000 — Standard Classification System for Rubber Products in Auto-
motive Applications.
ANSI/AWWA C110/A21.10 — American National Standard for Ductile-Iron
and Gray-Iron Fittings, 3 In. Through 48 In. (75 mm Through 1,200 mm), for Water
and Other Liquids.
ANSI/AWWA C111/A21.11 — American National Standard for Rubber-Gasket
Joints for Ductile-Iron and Gray-Iron Pressure Pipe and Fittings.
ANSI/AWWA C550 — Standard for Protective Epoxy Interior Coatings for
Valves and Hydrants.
Fed. Spec.* HH-P-106d — Packing; Flax or Hemp.
Fed. Spec. TT-C-494b — Coating Compound, Bituminous, Solvent Type, Acid
Resistant.
MSS† SP-9 — Spot Facing for Bronze, Iron and Steel Flanges.
MSS SP-60 — Connecting Flange Joint Between Tapping Sleeves and Tapping
Valves.
Sec. 1.4 Data to Be Supplied by Manufacturer
If requested by the purchaser, the manufacturer shall furnish the following
information when filling orders for resilient-seated gate valves.
1.4.1 Catalog data. The manufacturer shall supply catalog data, including
illustrations and a parts list, that identifies the materials to be used for making
various parts. The information shall be in sufficient detail to serve as a guide in the
assembly and disassembly of the valve and for ordering repair parts.
1.4.2 Weight information. The manufacturer shall furnish a statement of the
net assembled weight for each size of valve exclusive of joint accessories.
1.4.3 Assembly drawings. The manufacturer shall submit to the purchaser one
set of drawings showing the principal dimensions, construction details, and materi-
als used for all parts of the valve. All work shall be done and all valves shall be
furnished in accordance with these drawings after the drawings have been reviewed
and accepted by the purchaser.

*Federal Specifications available from Naval Publications and Forms Center, 5801 Tabor
Ave., Philadelphia, PA 19120.
†Manufacturers Standardization Society of the Valve and Fittings Industry, 127 Park St.
NE, Vienna, VA 22180.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
4 AWWA C509-94

Sec. 1.5 Affidavit of Compliance

The manufacturer shall, when required by the purchaser’s specifications, fur-
nish the purchaser with an affidavit stating that the valve and all materials used in
its construction conform to the applicable requirements of this standard and the
purchaser’s specifications, and that all tests specified therein have been performed
and all test requirements have been met.

SECTION 2: MATERIALS
Sec. 2.1 General
When reference is made to ANSI, ASTM, AWWA, or other standards, it shall
be understood that the latest revision thereof shall apply. All materials used in
valves produced under this standard shall conform to the requirements stipulated in
the following sections.

Sec. 2.2 Physical and Chemical Properties

The requirements of ANSI, ASTM, AWWA, or other standards referenced in
this text shall govern the physical and chemical characteristics of the valve compo-
nents. Whenever valve components are to be made in conformance with AWWA,
ANSI, ASTM, or other standards that include test requirements or testing proce-
dures, such requirements or procedures shall be complied with by the manufacturer.
The records of all tests shall, if required by the purchaser’s specifications, be made
available to the purchaser.
2.2.1 Gray iron. Gray iron shall conform to or exceed the requirements of
ASTM A126 class B.
2.2.2 Ductile iron. Ductile iron shall conform to the requirements of ASTM
A395 or ASTM A536.
2.2.3 Steel. Carbon–steel castings, when used, shall be ASTM A27 grade
U-60-30 or equal.
2.2.4 Brass or bronze. Brass or bronze used in valves shall comply with the
following:
2.2.4.1 Valve components of brass or bronze shall be made to ASTM or Copper
Development Association* (CDA) recognized alloy specifications.
2.2.4.2 The chemical and physical requirements shown in Table 1 shall apply.
2.2.4.3 Any bronze alloy used in the cold-worked condition shall be capable of
passing the mercurous nitrate test in accordance with ASTM B154 to minimize sus-
ceptibility to stress corrosion.
2.2.4.4 Waters in some areas promote galvanic corrosion in the form of dezinc-
ification or dealuminization. Grades B and C bronze shall not be used in such
waters. If aluminum bronze is used, the alloys shall be inhibited against dealumini-
zation by proper application of a temper anneal or other suitable means.
2.2.4.5 Bronze components that contact drinking water shall not contain more
than 8 percent lead (US Safe Drinking Water Act Amendments of 1986).

*Copper Development Association, Greenwich Office Park 2, P.O. Box 1840, Greenwich, CT
06836-1840.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 5

Table 1 Chemical and physical requirements for bronze used in resilient-seated gate valves

Minimum Minimum
Yield Elongation Copper Zinc
Grade of Strength in 2 in. (50.8 mm)* Minimum Maximum
Bronze psi (kPa) % % %
A 14,000 (96,500) 15 79 16
B 20,000 (137,800) 15 57 —
C 32,000 (220,500) 10 57 —
D 20,000 (137,800) 15 79 16
E 32,000 (220,500) 10 79 16
*Throat length of sample.

2.2.5 Gaskets. Gasket material shall be made of inorganic mineral fiber, rub-
ber composition, or paper that is free from corrosive ingredients. O-rings or other
suitable elastomeric seals may be used for gaskets.
2.2.6 O-rings. O-rings shall meet the requirements of ASTM D2000 and have
physical properties suitable for the application.
2.2.7 Coatings. Unless otherwise specified by the purchaser, valve coatings,
as specified in Sec. 5.2., shall at a minimum conform to Fed. Spec. TT-C-494b or
ANSI/AWWA C550.
2.2.8 Elastomers. Elastomers shall comply with the following:
2.2.8.1 Rubber seats shall be resistant to microbiological attack, copper poison-
ing, and ozone attack.
2.2.8.2 Rubber-seat compounds shall contain no more than 8 parts per million
(ppm) of copper ion and shall include copper inhibitors to prevent copper degrada-
tion of the rubber material.
2.2.8.3 Rubber-seat compounds shall be capable of withstanding an ozone
resistance test when tested in accordance with ASTM D1149. The tests shall be
conducted on unstressed samples for 70 h at 104°F (40°C) with an ozone concentra-
tion of 50 parts per hundred million (pphm) without visible cracking in the surfaces
of the test samples after the tests.
2.2.8.4 Rubber-seat compounds shall have a maximum compression set value
of 20 percent when tested in accordance with ASTM D395, method B, for 22 h at
158°F (70°C).
2.2.8.5 Rubber-seat compounds shall contain no more than 1.5 parts of wax
per 100 parts of rubber hydrocarbon and shall have less than 2 percent volume
increase when tested in accordance with ASTM D471 after being immersed in
distilled water at 73.4°F ± 2°F (23°C ± 1°C) for 70 h. Reclaimed rubber shall not
be used.
2.2.8.6 Rubber-seat compounds shall be free of vegetable oils, vegetable-oil
derivatives, animal fats, and animal oils.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
6 AWWA C509-94

SECTION 3: GENERAL DESIGN

Sec. 3.1 Structural Design
All parts of all valves shall be designed to withstand, without being structur-
ally damaged, (1) an internal test pressure of twice the rated design working
pressure of the valve and (2) the full rated internal working pressure when the
closure member is cycled once from a fully open to a fully closed position against the
full rated unbalanced working water pressure. In addition to these pressure require-
ments, the valve assembly and mechanism shall be capable of withstanding an input
torque as follows: 3 in. and 4 in. (75 mm and 100 mm) NPS — 200 ft-lb (270 N m); ⋅
6 in. (150 mm), 8 in. (200 mm), 10 in. (250 mm), and 12 in. (300 mm) NPS — 300
⋅
ft-lb (406 N m). For sizes larger than 12 in. (300 mm), consult the manufacturer.

Sec. 3.2 Size of Waterway

With the valve open, an unobstructed waterway shall be provided. The water-
way shall have a diameter equal to or larger than the full nominal diameter of the
valve. For tapping valves, the size of the waterway shall include the appropriate
clearance for the diameter of the tapping machine cutter recommended by the valve
manufacturer. Some valves may require an undersized cutter, which is smaller than
the nominal diameter of the valve.

SECTION 4: DETAILED DESIGN

Sec. 4.1 Parts to Be Made of Gray or Ductile Iron
The following parts of the valve shall be made of either gray or ductile iron:
bonnet, body, yoke, handwheel, wrench nut, O-ring packing plate or seal plate, and
gland follower. The gate may be made of gray or ductile iron.

Sec. 4.2 Parts to Be Made of Brass or Bronze

The stem nuts, glands, and bushings for NRS valves, and the followers or
glands and bonnet bushings on OS&Y valves, shall be made of grade A, B, C, D, or
E bronze. The stem shall be made of cast, forged, or rolled grade B, C, D, or E
bronze. The gate may be made of bronze grade A, B, C, D, or E.
Sec. 4.3 Body and Bonnet
4.3.1 Shell thickness. Shell thickness measurements taken at points diametri-
cally opposite to each other shall, when added together and divided by two, equal or
exceed the minimum metal thicknesses given in Table 2. Shell thickness at no point
shall be more than 12.5 percent thinner than the minimum metal thickness called
for in Table 2, and no continuous area of deficient thickness shall exceed 12.5 per-
cent of the pressure-containing shell area of the casting.
4.3.2 Yokes on OS&Y valves. On OS&Y valves, the yoke on bonnets may be
integral or of bolted-on construction. The design shall be such that a hand cannot be
jammed between a yoke and the handwheel.
4.3.3 Stem opening on OS&Y valves. With OS&Y valves, the opening through
the bonnet for the stem shall be bushed with grade A, B, C, D, or E bronze, finished

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 7

Table 2 Minimum thickness of body and bonnet

Valve Minimum
Diameter Thickness*
NPS, in. (mm) in. (in. fractions) (mm)
3 (75) 0.37 (3⁄8) (9)
4 (100) 0.40 (13⁄32) (10)
6 (150) 0.43 (7⁄16) (11)
8 (200) 0.50 (1⁄2) (13)
10 (250) 0.63 (5⁄8) (16)
12 (300) 0.68 (11⁄16) (17)
16 (400) 0.85 (27⁄32) (22)
20 (500) 0.97 (31⁄32) (25)
*The decimal value should be used when the two expressions are not exactly equivalent.

on the underside or otherwise designed to make a joint with the stem or stem nut
when the gate is wide open.
Sec. 4.4 Bolting
Bolting materials shall develop the physical strength requirements of ASTM
A307 and may have either regular square or hexagonal heads with dimensions con-
forming to ANSI B18.2.1. Bolts, studs, and nuts shall be (1) cadmium-plated (ASTM
B766) or zinc-coated (ASTM A153 or ASTM B633), or (2) rustproofed by some other
process disclosed to and acceptable to the purchaser. The purchaser may require
that bolts, studs, and nuts shall be made from a specified corrosion-resistant mate-
rial, such as low-zinc bronze, nickel–copper alloy, or stainless steel.

Sec. 4.5 Valve Ends

End connections shall conform to one of the following requirements:
4.5.1 Flanged ends. The end flanges of flanged valves shall conform to dimen-
sions and drillings of ANSI B16.1 class 125, or ANSI/AWWA C110/A21.10 unless
explicitly provided otherwise in the purchaser’s specifications. Unless spot-facing is
required by the purchaser’s specifications, the bolt holes of the end flanges shall not
be spot-faced except when the thickness at any point within the spot-face area, as
defined in MSS SP-9, exceeds the required minimum thickness by more than that
indicated in Table 3 or if the flange is not sufficiently flat. If the foregoing limit is
exceeded, either spot-facing or back-facing may be used to meet the requirements.
When required, all spot-facing shall be done in accordance with MSS SP-9. Bolt
holes shall straddle the vertical centerline of the valve, unless otherwise specified by
the purchaser. The laying lengths of flanged valves 12 in. (300 mm) and smaller
shall conform to the requirements for double-disc gate valves listed in Table 1 of
ANSI/ASME B16.10.
4.5.2 Mechanical-joint ends. Mechanical-joint bell dimensions shall conform to
ANSI/AWWA C111/A21.11. Slots with the same width as the diameter of the bolt
holes may be provided instead of holes in the bell flange at those places where the
valve body and bonnet interfere with the joint assembly.
4.5.3 Push-on joint ends. Push-on joints shall conform to the requirements of
ANSI/AWWA C111/A21.11.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
8 AWWA C509-94

Table 3 Excess flange thickness

Nominal Valve Size Excess Thickness (minimum)

NPS, in. (mm) in. (mm)
3–12 (75–300) 1⁄8 (3.2)
16–20 (400–600) 3⁄16 (4.8)

4.5.4 Tapping-valve ends.

4.5.4.1 The end flange of a tapping valve that forms a joint with the tapping
sleeve shall conform to the dimensions of MSS SP-60 in sizes 3 in. (75 mm) through
12 in. (300 mm) NPS. For larger sizes, flange dimensions shall be as agreed to by
the purchaser and supplier.
4.5.4.2 The connecting flange of the tapping valve mating with the tapping
machine must be parallel and concentric with the opposite flange and concentric
with the waterway to provide proper alignment for the tapping operation.
Sec. 4.6 Guides
If guiding is necessary to obtain shut off, the design shall be such that corro-
sion in the guide area does not affect sealing.

Sec. 4.7 Stem and Stem Nut

4.7.1 Stem collars. All stem collars shall be made integral with stems on NRS
valves. The stem on OS&Y valves shall be so constructed as to make a backseat
with the pressure side of the bonnet or bushing when the gate is wide open. The
backseat should allow repacking according to Sec. 4.8.1.
4.7.2 Threads. The threads of stems and stem nuts (disc bushings) shall be of
Acme, modified Acme, or one-half V-type.
4.7.3 Thread forming. Stems and stem nuts shall be threaded straight and
true and shall work true and smooth and in perfect line throughout the lift of open-
ing and thrust of closing the valve.
4.7.4 Diameter. The stem diameters and turns to open shall be as shown in
Table 4.
4.7.5 OS&Y stems. OS&Y valve stems shall be of sufficient length so as to be
at least flush with the top of the yoke nut after the gate is fully closed. The design
shall prevent any possibility of the gate leaving the stem or turning during the
operation of the valve.
4.7.6 Materials. Valve stems shall be cast, forged, or rolled bronze. Bronze
shall be grade B, C, D, or E. Stem nuts shall be grade A, B, C, D, or E bronze.
4.7.7 Stress corrosion. Valve stems and valve parts manufactured from some
grades of manganese bronze or some other materials are subject to stress corrosion.
The manufacturer shall design the valve and select materials to minimize stress
corrosion.
Sec. 4.8 Stem Sealing
4.8.1 Stuffing boxes. The stuffing box shall be designed so that the valve can
be packed under pressure when in the fully open position.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 9

Table 4 Minimum diameter of stem and minimum number of turns to open

OS&Y Valves
NRS Valves
Minimum
Minimum Minimum Diameter of Stem Minimum
Diameter of Stem Number of Unthreaded Section Number of
Valve Size (at base of thread)* Turns of Stem and Thread OD† Turns of Stem
NPS, in. (mm) in. (mm) to Open in. (mm) to Open‡
3 (75) 0.859 (21.82) 9 3⁄4 (19.1) 7
4 (100) 0.859 (21.82) 12 1 (25.4) 9
6 (150) 1.000 (25.40) 18 1 1⁄8 (28.6) 18
8 (200) 1.000 (25.40) 24 1 1⁄4 (31.8) 25
10 (250) 1.125 (28.58) 30 1 3⁄8 (34.9) 31
12 (300) 1.188 (30.18) 36 1 3⁄8 (34.9) 37
16 (400) 1.438 (36.53) 48 1 1⁄2 (38.1) 48
20 (500) 1.750 (44.45) 40 — — —
*The diameter of the stem at the base of the thread or at any point below that portion shaped to receive the wrench nut
on NRS valves, or the minimum diameter of the stem unthreaded section and thread OD for OS&Y valves, shall not be less
than specified.
†Outside diameter.
‡Valves shown for 6–12 in. (150–300 mm) NPS sizes are for single-lead threads. If a double-lead thread is used, minimum
turns become 13, 17, 21, and 25 for sizes 6–12 in. (150–300 mm) NPS inclusive.

4.8.1.1 On NRS valves, the stem opening, thrust-bearing recess, and bonnet
face of the stuffing box shall be machined or finished in a manner that provides a
smooth surface that is either parallel or perpendicular to the stem axis within 0.5°.
4.8.1.2 Stuffing boxes shall have a depth not less than the diameter of the
valve stem. The internal diameter shall be large enough to contain adequate pack-
ing to prevent leakage around the stem.
4.8.2 O-rings. When an O-ring or other pressure-actuated stem seal is used,
the design shall incorporate two such seals. The dimensions of such seals shall be in
accordance with AS-568A. The sealing system shall be designed to remain water-
tight at pressures required by this standard. The seals shall be designed for
dynamic applications.
4.8.2.1 The valve shall be so designed that the seal above the stem collar can
be replaced with the valve under pressure in the fully open position.
4.8.3 Materials. A stuffing box or O-ring packing plate shall be made of cast
iron. Thrust surfaces and stem openings, if bushed, or stem-seal cartridges shall be
made of grade A, B, C, D, or E bronze or a synthetic polymer with physical proper-
ties suitable for the application. Stem-seal bolts and nuts shall conform to the
requirements specified in Sec. 4.4.

Sec. 4.9 Packing

4.9.1 Material. Stuffing-box packing shall be made of flax conforming to Fed.
Spec. HH-P-106d or other appropriate material. Hemp, asbestos, or jute packing
shall not be used.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
10 AWWA C509-94

4.9.2 Installation. Stuffing boxes shall be packed properly and ready for serv-
ice when valves are delivered to the purchaser. Adjustment of stuffing-box bolts may
be required to seal leakage at the time of installation.
Sec. 4.10 Packing Glands, Gland Flanges, Gland Bolts, and Gland-Bolt Nuts
The packing-gland assembly shall be of solid, solid-bushed, or two-piece design.
Gland flanges (followers) may be formed as a flanged end on the gland or as a
separate part.
4.10.1 Material. Packing glands for valves sizes 12 in. (300 mm) NPS and
smaller shall be made of grade A, B, C, D, or E bronze. Packing glands for valves
larger than 12 in. (300 mm) NPS may be made of cast iron and bushings of grade A,
B, C, D, or E bronze.
4.10.2 Packing-gland flange. If a packing-gland flange (follower) is used, it
shall be made of either cast iron or grade A, B, C, D, or E bronze.
4.10.3 Packing-gland bolts. Packing-gland bolts shall be made either of grade
B, C, D, or E bronze or rustproofed steel according to Sec. 4.4. Gland-bolt nuts shall
be made of grade B, C, D, or E bronze.

Sec. 4.11 Wrench Nuts and Handwheels

Wrench nuts and handwheels shall be made of gray iron or ductile iron. Unless
otherwise explicitly required by the purchaser’s specifications, the wrench nuts shall
be 115⁄16 in. (49.2 mm) square at the top, 2 in. (50.8 mm) square at the base, and
13⁄4 in. (44.5 mm) high. The outside diameter of handwheels shall not be less than
those given in Table 5. Nuts shall have a flanged base on which shall be cast an
arrow at least 2 in. (50.8 mm) long showing the direction of opening. The word
“OPEN,” in 1⁄2-in. (12.7-mm) or larger letters, shall be cast on the nut to indicate
clearly the direction to turn the wrench when opening the valve. Handwheels shall
be of the spoke type only. Webbed or disc types are not permissible. An arrow show-
ing the direction to turn the handwheel to open the valve, with the word “OPEN” in
1⁄2-in. (12.7-mm) or larger letters in a break in the arrow shaft, shall be cast on the
rim of the handwheel so as to be readily readable.
4.11.1 Operating mechanism. NRS valves are to be supplied with wrench nuts
for buried service and handwheels for aboveground service. OS&Y valves are to be
supplied with handwheels.

Table 5 Outside diameter of handwheels*

Minimum Diameter
Size of Valve of Handwheel
NPS, in. (mm) in. (mm)
3 (75) 7 (178)
4 (100) 10 (254)
6 (150) 12 (305)
8 (200) 14 (356)
10 (250) 16 (406)
12 (300) 16 (406)
*For sizes larger than 12 in. (300 mm), consult the manufacturer.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 11

4.11.2 Direction of opening. For OS&Y valves, the standard direction of open-
ing is counterclockwise as viewed from the top. Valves opening in the opposite
direction (clockwise) may be supplied if specifically ordered. Both directions of open-
ing are considered standard for NRS valves.
4.11.3 Method of securing. Wrench nuts shall be fitted to the top of the valve
stem and secured in position by mechanical means.
4.11.4 Access to packing-gland bolts. The flanged base of the wrench nut may
be shaped or cut away to permit access from the ground surface to the packing-
gland bolts with an extension socket wrench.
4.11.5 Color coding. Wrench nuts and handwheels that open the valve by
turning to the right (clockwise) shall be painted red. Wrench nuts and handwheels
that open the valve by turning to the left (counterclockwise) shall be painted black.
Sec. 4.12 Gearing
If required by the purchaser’s specifications, gears shall be accurately formed
and smooth running, with a pinion shaft of bronze or equivalent material operating
in a bronze, self-lubricating or permanently sealed antifriction bearing.
4.12.1 Material. Geared valves shall be equipped with steel gears unless cast-
iron gears are explicitly required by the purchaser’s specifications. Pinions shall be
steel. Material for steel gears shall be ASTM A27 grade U-60-30 or equal.
4.12.2 Gear Ratio. Gear ratios shall not be less than those shown in Table 6.

Sec. 4.13 Gear Cases

Valves using O-ring or V-type stem seals may have the gear case attached
directly to the valve. When geared valves are furnished, enclosed gear cases are
required unless definitely excluded by the purchaser’s requirements.
Two types of gear cases may be furnished — the extended type or the totally
enclosed type. The extended type shall be attached to the bonnet of the valve in
such a manner as to permit repacking of the stuffing box of the valve without
detaching the gear case. The totally enclosed type shall enclose both stuffing box
and gearing.
Sec. 4.14 Indicators
When required by the purchaser’s specifications, geared valves shall be
equipped with indicators to show the position of the gate in relation to the waterway.

Sec. 4.15 Gaskets

Gaskets, O-rings, or other suitable elastomeric seals shall be used on all
flanged joints intended to be watertight.

Table 6 Gear ratios

Valve Diameter
NPS, in. (mm) Minimum Gear Ratio
16 (400) 2:1
20 (500) 2:1

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
12 AWWA C509-94

Sec. 4.16 Valve Seats

Resilient seats shall be applied to the gate and shall seat against a corrosion-
resistant surface. The surface may be either metallic or nonmetallic, applied in a
manner to withstand the action of line fluids and the operation of the sealing gate
under long-term service. A metallic surface shall have a corrosion resistance equiva-
lent to or better than bronze. A nonmetallic surface shall be in compliance with
ANSI/AWWA C550. Resilient seats shall be bonded or mechanically attached to the
gate. The method used for bonding or vulcanizing shall be proved by ASTM D429;
either method A or method B. For method A, the minimum strength shall not be
less than 250 psi (1,725 kPa). For method B, the peel strength shall not be less than
75 lb/in. (9.3 kg/m).
All exposed mechanical attaching devices and hardware used to retain the
resilient seat shall be made of a corrosion-resistant material.

SECTION 5: FABRICATION
Sec. 5.1 Workmanship
5.1.1 Interchangeable parts. All parts shall conform to their required dimen-
sions and shall be free from defects that could prevent proper functioning of the
valve. When assembled, valves manufactured in accordance with this standard shall
be well-fitted and shall operate smoothly. All like parts of valves of the same model
and size produced by the same manufacturer shall be interchangeable.
5.1.2 Castings. All castings shall be clean and sound, without defects that will
weaken their structure or impair their service. Plugging, welding, or repairing of
cosmetic defects is allowed. Repairing of structural defects is not allowed unless
agreed to by the purchaser. Repaired valves shall comply with the testing require-
ments of this standard after repairs have been made. Repairs within the bolt circle
of any flange face are not allowed.

Sec. 5.2 Coating

5.2.1 Interior ferrous surfaces. A coating conforming to ANSI/AWWA C550
shall be applied to the interior ferrous surfaces of the valve body that will be in
contact with liquid.
Other exposed interior ferrous surfaces, except finished or bearing surfaces,
shall be coated with a material specified in Sec. 2.2.7.
5.2.2 Exterior ferrous surfaces. A coating material as specified in Sec. 2.2.7
shall be applied to all exterior ferrous surfaces except fasteners.

SECTION 6: TESTING, INSPECTION, AND REJECTION

Sec. 6.1 Proof of Design Testing
6.1.1 Hydrostatic test. One prototype valve of each size and class of a manu-
facturer’s design shall be hydrostatically tested with twice the specified rated
pressure applied to one side of the gate and zero pressure applied to the other side.
The test is to be made in each direction across the gate. During this hydrostatic test,

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 13

the manufacturer may make special provisions to prevent leakage past the seats. No
part of the valve or gate shall be permanently deformed by the test.
6.1.2 Torque test. A prototype of each size of valve shall be overtorqued in the
closed and open positions to demonstrate that there is no distortion of the valve
stem or damage to the resilient seat as evidenced by failure to seal at rated pres-
⋅
sure. The applied torque shall be 250 ft-lb (340 N m) for 3-in. (75-mm) and 4-in.
⋅
(100-mm) NPS valves; 350 ft-lb (475 N m) for 6-in. (150-mm), 8-in. (200-mm), 10-in.
(250-mm), and 12-in. (300-mm) NPS valves; and 400 ft-lb (545 N m) for 16-in. (400- ⋅
mm) and 20-in. (500-mm) NPS valves. Torque shall be directly applied to the valve
stem.
6.1.3 Leakage test. Two prototype valves of each size chosen by the manufac-
turer to represent the extremes of seat compression shall be fully opened and closed
to a seal for 500 complete cycles with sufficient flow that the valve is at the rated
working pressure for the pressure differential at the point of closing. The valves
shall be drip-tight under rated pressure differential applied alternately to each side
of the gate after completion of the tests.
6.1.4 Pressure test. One prototype of each valve size shall be tested to
2.5 times the rated working pressure with the gate in the open position. There shall
be no rupture or cracking of the valve body, valve bonnet, or seal plate. Leakage at
pressure-containing joints shall not be a cause for failure of the test.
Sec. 6.2 Production Testing
After manufacture, each gate valve shall be subjected to operation and hydro-
static tests at the manufacturer’s plant as specified in this section.
6.2.1 Operation test. Each valve shall be operated through a complete cycle in
the position for which it was designed to ensure free and proper functioning of all
parts in the intended manner. Any defects in workmanship shall be corrected and
the test repeated until satisfactory performance is demonstrated.
6.2.2 Shell test. A hydrostatic test pressure equal to twice the rated working
pressure of the valve shall be applied to the assembled valve with the gate in the
open position. The test shall show no leakage through the metal, pressure-containing
joints, or stem seals.
6.2.3 Seat test. A test shall be made from each direction at rated working
pressure to prove the sealing ability of each valve from both directions of flow. The
test shall show no leakage through the metal, pressure-containing joints, or past the
seat.

Sec. 6.3 Plant Inspection and Rejection

All work performed in accordance with this standard, except prototype testing,
shall be subject to inspection and acceptance by the purchaser. The purchaser shall
at all times have access to all places of manufacture where materials are being
produced or fabricated, or where tests are conducted. The purchaser shall be
accorded full facilities for inspection and observation of tests during plant inspec-
tion. Any valve or part not conforming to the requirements of this standard shall be
made satisfactory or shall be rejected and repaired or replaced by the manufacturer.
Repaired valves must be acceptable to the purchaser and specifically accepted when
submitted or resubmitted. Whether the purchaser has a representative at the plant
or not, an affidavit of compliance may be required from the manufacturer as pro-
vided in Sec. 1.5 of this standard.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
14 AWWA C509-94

SECTION 7: MARKING AND SHIPPING

Sec. 7.1 Marking
Markings shall be cast on the bonnet or body of each valve and shall show the
manufacturer’s name or mark, the year the valve casting was made, the size of the
valve, and the designation of working water pressure, for example, “200W.” Special
markings in addition to these can be supplied when specified by the purchaser’s
requirements on agreement between purchaser and manufacturer.
Sec. 7.2 Preparation for Shipment
Valves shall be complete in all details when shipped. The manufacturer shall
use reasonable care in preparing valves for shipment. Valves shall be drained before
shipment.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 APPENDIX A
Installation, Operation, and Maintenance
of Resilient-Seated Gate Valves

This appendix is for information only and is not a part of AWWA C509.

SECTION A.1: GENERAL

Resilient-seated gate valves form a significant component of many fire-fighting
or water-distribution systems. Failure of a resilient-seated gate valve in such sys-
tems, either due to faulty installation or improper maintenance, could result in
extensive damage and costly repairs. In addition, many resilient-seated gate valves
are installed in buried-service or underground applications. Problems with or mal-
functions of the valves due to faulty installation or improper maintenance can result
in extensive and costly unearthing operations to effectively correct or eliminate the
problem. Many resilient-seated gate-valve problems and failures can be traced back
to improper installation, operation, or maintenance procedures.

SECTION A.2: UNLOADING

All valves should be unloaded carefully. Each valve should be carefully lowered
from the truck to the ground; it should not be dropped. In the case of larger valves,
forklifts or slings around the body of the valve or under the skids should be used for
unloading. Only hoists and slings with adequate load capacity to handle the weight
of the valve or valves should be used. Hoists should not be hooked into or chains
fastened around yokes, gearing, motors, cylinders, or handwheels. Failure to care-
fully follow these recommendations is likely to result in damage to the valve.

SECTION A.3: INSPECTION PRIOR TO INSTALLATION

Resilient-seated gate valves should be inspected at the time of receipt for dam-
age in shipment. The initial inspection should verify compliance with specifications,
direction of opening, size and shape of operating nut, number of turns to open or
close, and type of end connections. A visual inspection of the seating surfaces should
be performed to detect any damage in shipment or scoring of the seating surfaces.
Inspection personnel should look for bent stems, broken handwheels, cracked parts,
loose bolts, missing parts and accessories, and any other evidence of mishandling
during shipment. Each valve should be operated through one complete opening-and-
closing cycle in the position in which it is to be installed.

15

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
16 AWWA C509-94

SECTION A.4: STORAGE

Valves should be stored in the fully closed position to prevent the entry of
foreign material that could cause damage to the seating surfaces. Whenever practi-
cal, valves should be stored indoors. If outside storage is required, means should be
provided to protect the operating mechanism, including gears, motor actuators, and
cylinders, from weather elements. During outside storage, valves should be pro-
tected from the weather, sunlight, ozone, and foreign materials. In colder climates
where valves may be subject to freezing temperatures, it is absolutely essential to
remove water from the valve interior and close the valve before storage. Failure to
do so may result in a cracked valve casting and/or deterioration of the resilient seat
material.

SECTION A.5: INSTALLATION

Instructions supplied by manufacturers should be reviewed in detail before
valves are installed. At the jobsite prior to installation, each valve should be visually
inspected and any foreign material in the interior portion of the valve should be
removed. A detailed inspection of the valve as outlined in Sec. A.3 should be per-
formed prior to installation.
Sec. A.5.1 Bolts
All bolts should be checked for proper tightness and protected by the installer
to prevent corrosion, either with a suitable paint or by polyethylene wrapping.

Sec. A.5.2 Underground Installation

Valves in water-distribution lines shall, where practical, be located in easily
accessible areas.
A.5.2.1 During installation there is the possibility of foreign materials inadver-
tently entering the valve. Foreign material can damage internal working parts
during operation of the gate valve. For this reason, gate valves should be installed
in the closed position. Each valve should be placed on firm footing in the trench to
prevent settling and excessive strain on the connection to the pipe. Piping systems
should be supported and aligned to avoid damage to the valve.
A.5.2.2 A valve box or vault should be provided for each valve used in a bur-
ied-service application. The valve box should be installed so as not to transmit shock
loads or stress to the valve. The valve box should be centered over the operating nut
of the valve with the box cover flush with the surface of the finished area or such
other level as directed by the owner. Valve boxes should be of such design that a
traffic load on the top of the box is not transmitted to the valve.
A.5.2.3 Valves buried in unusually deep trenches should have special provi-
sions for operating the valve — either a riser on the stem to permit use of a normal
key or a notation on valve records that a long key will be required.
A.5.2.4 When valves with exposed gearing or operating mechanisms are
installed belowground, a vault designed to allow pipe clearance and prevent settling
on the pipe should be provided. The operating nut should be accessible from the top
opening of the vault with a valve key. The size of the vault should provide for easy
removal of the valve bonnet and internal parts of the valve for purposes of repair.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 17

Consideration should be given to the possible entry of groundwater and/or surface

water and to the need to provide for the disposal of such water.
Sec. A.5.3 Aboveground Installation
Valves installed aboveground or in a plant piping system should be supported
and aligned to avoid damage to the valves. Valves should not be used to correct the
misalignment of piping.
Sec. A.5.4 Inspection
After installation and before pressurization of the valve, all pressure-containing
bolting (bonnet, seal plate, packing gland, and end connections) should be inspected
for adequate tightness to prevent leakage. In addition, an inspection should be made
for adequate tightness of all tapped and plugged openings to the valve interior.
Proper inspection at this time will minimize the possibility of leaks after pressuriza-
tion of the piping system.
Sec. A.5.5 Testing
In order to prevent time lost searching for leaks, it is recommended that valve
excavations not be backfilled until after pressure tests have been made. After instal-
lation, it is desirable to test newly installed piping sections, including valves, at
some pressure above the system design pressure. The test pressure should not
exceed the rated working pressure of the valve. After the test, steps should be taken
to relieve any trapped pressure in the body of the valve. The resilient-seated gate
valve should not be operated in either the opening or closing direction at differential
pressures above the rated working pressure. It should be noted that valves seat
better at or near the rated working pressure of the valve. It is also recognized that
wear or foreign material may damage valve seating surfaces and may cause leakage.

Sec. A.5.6 Records

On completion of the installation, valve location, size, make, type, date of
installation, number of turns to open, direction of opening, and other information
deemed pertinent should be entered on permanent records.
Sec. A.5.7 Application Hazards
Resilient-seated gate valves should not be installed in applications or for serv-
ice other than those recommended by the manufacturer.
A.5.7.1 Resilient-seated gate valves should not be installed in lines where serv-
ice pressure will exceed the rated working pressure of the valve.
A.5.7.2 Resilient-seated gate valves should not be used for throttling service
unless the design is specifically recommended for that purpose or approved in
advance by the manufacturer.
A.5.7.3 Resilient-seated gate valves should not be used in applications that are
exposed to freezing temperatures unless sufficient flow is maintained through the
valve or other protection is provided to prevent freezing.
A.5.7.4 Pipe, fittings, and valves installed in underground pipelines are gener-
ally joined with push-on or mechanical joints. These joints are considered
unrestrained-type joints since no significant restraint against longitudinal separa-
tion is provided.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
18 AWWA C509-94

Gate valves should not be installed at a dead end or near a bend in a pipeline
without proper and adequate restraint to support the valve and prevent it from
blowing off the end of the line.
It is good engineering practice to consider during design whether or not thrust
blocks, restrained joints, or other means of restraint are needed on or adjacent to
valves on pipelines and/or where unusual conditions exist, such as high internal
pressures, adjacent fittings, or unsuitable soils.
A.5.7.5 To prevent damage, 3-in. (75-mm) and 4-in. (100-mm) NPS resilient-
seated gate valves should not be operated with input torques greater than 200 ft-lb
(270 N⋅m). Gate valves 6 in. (150 mm) NPS to 12 in. (300 mm) NPS should not be
operated with input torques greater than 300 ft-lb (406 N ⋅m).

SECTION A.6: INSPECTION AND MAINTENANCE

Each valve should be operated through a full cycle and returned to its normal
position on a time schedule designed to prevent a buildup of tuberculation or other
deposits that could render the valve inoperable or prevent a tight shutoff. The inter-
val of time between operations of valves in critical locations, or valves subjected to
severe operating conditions, should be shorter than that for less important installa-
tions, but can be whatever time period is found to be satisfactory based on local
experience. The number of turns required to complete the operation cycle should be
recorded and compared with permanent installation records to ensure full gate
travel.
When using portable auxiliary power actuators with input torque capacities
exceeding the maximum operating torques recommended in Sec. A.5.7.5, extreme
care should be taken to avoid the application of excessive torque to the valve stem.
If the actuator has a torque-limiting device, it should be set below the values in
Sec. A.5.7.5. If there is no torque-limiting device, the recommended practice is to
stop the power actuator three or four turns before the valve is fully opened or fully
closed and then complete the operation manually.
Maintenance should be performed at the time a malfunction is discovered to
avoid a return trip to the same valve and to prevent forgetting about it altogether. A
recording system should be adopted that provides a written record of valve location,
condition, maintenance, and each subsequent inspection of the valve.

Sec. A.6.1 Inspection

Each valve should be operated through one complete operating cycle. If the
stem action is tight as a result of “hard-water” buildup on the stem threads, the
operation should be repeated several times until the opening and closing actions are
smooth and free. With the gate in the partially open position, a visual inspection
should be performed, where practical, to check for leakage at all joints, connections,
and areas of packing or seals. If leakage is observed, all defective O-rings, seals,
gaskets, or end-connection sealing members should be replaced. If the leakage can-
not be corrected immediately, the nature of the leakage should be reported promptly
to those who are responsible for repairs. If the valve is inoperable or irreparable, its
location should be clearly established to save time for repair crews. The condition of
the valve and, if possible, the gate position, should be reported to personnel

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
 GATE VALVES 19

responsible for repairs. In addition, fire departments and other appropriate munici-
pal departments should be informed that the valve is out of service.
Sec. A.6.2 Record Keeping
In order to carry out a meaningful inspection and maintenance program, it is
essential that the location, make, type, size, and date of installation of each valve be
recorded. Depending on the type of record-keeping system used, other information
may be entered in the permanent record. When a resilient-seated gate valve is
inspected, an entry should be made in the permanent record indicating the date of
inspection and condition of the valve. If repair work is necessary, it should be indi-
cated. On completion of the work, the nature of the repairs and date completed
should be recorded.

SECTION A.7: REPAIRS

Leakage, broken parts, hard operation, and other major defects should be cor-
rected by a repair crew as soon as possible after the defect has been reported. If
repairs are to be performed in the field, the repair crews should take a full comple-
ment of spare parts to the jobsite. Provisions should be made to isolate the defective
valve from water pressure and relieve internal trapped pressure prior to performing
any corrective maintenance. Disassembly of the valve should be accomplished in
accordance with the procedure supplied by the manufacturer. After repairing the
valve, the operating mechanism should be cycled through one complete operating
cycle. With full line pressure applied to the valve in the open position, an inspection
should be made to detect leakage in the areas around the seal plate, bonnet, packing
gland, and body-end connections. A record should be made to indicate that the valve
has been repaired and is in working condition. Any markings indicating that the
valve is inoperable should be removed. In addition, fire departments and other
appropriate municipal departments should be informed of the satisfactory repair of
the valve.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.
3P-2M-43509-2/97-RM Printed on recycled paper.

Copyright (C) 1998 American Water Works Association, All Rights Reserved.